Cementitious slab with bolt means



Jan. 3, 1967 A. SCHAICH 3,295,286

CEMENTITIOUS SLAB WITH BOLT MEANS Original Filed May 51. 1961 5Sheets-Sheet 1 INVENTOR. W/L BUR A 8617/1/61! Jan. 3, 1967 w. A. SCHAICH3,295,286

GEMENTITI'OUS SLAB WITH BOLT MEANS Original Filed May 51. 19 61 5 Sheets Sheet 2 INVENTOR, w/LauR A. JCHA/Cfi f SQJAQQQJA CEMENTITIOUS SLABWITH lBOLT MEANS Original Filed May 31. 1961 5 Sheets-Sheet :5

INVENTOR W/LBUR A. Jff/A/Cf/ k), sQ aaz fi United States Patent3,295,286 CEMENTHTIGUS SLAB WETH BULT MEANd Wiibur A. Schaich, Manatee,(thin, assignor to Uri ensiilinois, inc, a corporation of Ohio (Iriginalappiication May 31, N61, Ser. No. 113,942, now Patent No. 3,291,346.Divided and this application Dec. 3t 1964, Ser. No. 422,212

1 Elana. (@l. 52-584} This application is a division of my co-pendingapplication Serial No. 113,942 and assigned to the assignee of thisapplication, now US. Patent 3,201,846.

This invention relates to a novel slab and an improved method ofmanufacturing such slabs to provide therein the apertures necessary forassembling the slabs according to the method of the invention.

There has been an increasing interest in the construction industry inthe utilization of lightweight slabs or panels of cementitious materialsto form the side walls of residential and commercial structures. Onepopular form of such panels constitutes a material popularly known asfoam concrete which is manufactured by the introduction of a foaming orfoamable material into a cementitious slurry so that a large number ofmacroscopic cells are produced in which each individual air cell issurrounded by the cementitious slurry. When this material is permittedto harden and set, either by air drying or by an accelerated drying inan autoclave, the resulting product will have densities on the order of40 pounds per cubic foot or less, so that slabs or panels of suchmaterial ranging in height up to ten or twelve feet and in width fromtwo to four feet can be efiiciently and economically produced bycontinuous production operations in a factory and then shipped to thebuilding erection site and there assembled into an integral wallstructure.

In the assembling of such wall structures, the cementitious slabs orpanels are most conveniently erected in sideby'side relationship withthe major dimension of the panel constituting the height dimension ofthe finished wall. Obviously, some form of rigid connection must beprovided between adjacent panels to withstand lateral stresses imposedon the building wall by the wind. Additionally, a weather-tight jointmust be provided between the edges of the adjacent panels. In accordancewith the method of this invention, each panel is rigidly secured to theadjacent panels on each side by an internally disposed bolt-likeelement. The restraining forces exerted by such bolt-like elements mayalso be utilized to produce a compression of sealing material insertedbetween the contiguous edges of the panels, if desired. The resultingwall structure will thus be integrally united so far as resistance tolateral forces are concerned, will have all joints sealed against theentry of water or moisture vapor and all of the bolt-like fasteningelements will be concealed from View.

To practice the panel assembly method of this invention, it is essentialthat each of the cementitious slabs be provided with at least twospecially shaped openings or holes which respectively traverse the widthdimension of the slab or panel, with at least one of such holes beinglocated near the lower portion of the slab or panel and at least oneother such hole being located adjacent the top portion of the slab orpanel. While it is possible to produce such holes by a drillingoperation on the panels after their manufacture, and to insert separatecountersunk mechanisms for keeping boltheads from turning, a furtherfeature of this invention is the provision of an improved method forincorporating such dual purpose holes or openings in the slabs or panelsduring the manufacture of the cementitious slab or panel.

Accordingly, it is an object of this invention to provide an improvedmethod for assembling a plurality of cementitious slabs or panels inupright, side-by-side relationship to form a building wall.

3,Z%,Z8h Patented Jan. 3, 196? A further object of this invention is toprovide an improved cementitious slab or panel having specially shapedand arranged openings to facilitate the assembly of such panels inupright, side-by-side relationship.

Still another object of this invention is to provide an improved methodfor fabricating cementitious slabs or panels with specially shapedopenings extending transversely of the panels and parallel to the widthdimension thereof.

The specific nature of this invention, as well as other objects andadvantages thereof, will become apparent to those skilled in the artfrom the following detailed description, taken in conjunction with theannexed sheets of drawings, on which:

FIG. 1 is a side elevational view of one of the cementitious panelsutilized in the wall of FIG. 2;

FIG. 2 is a vertical sectional view, taken on the line 22 of FIG. 1,showing a plurality of cementitious panels disposed in side-by-siderelationship;

FIG. 3 is an enlarged scale, partially sectional view of a portion ofthe wall of FIG. 2;

FIG. 4 is a partial sectional view taken on the line i--4 of FIG. 3;

FIG. 5 is a sectional view taken on the line 5-5 of FIG. 4, but with thebolt element removed;

FIG. 6 is a side elevational view of the head of the boltlike memberutilized to assemble the Wall of FIG. 2;

FIG. 7 is a front elevational view of the bolthead of FIG. 6;

FIG. 8 is a top elevational view of the bolthead of FIG. 6;

FIG. 9 is a top elevational view of a mold structure embodying thisinvention which may be used for simultaneous casting of a plurality ofcementitious slabs or panels utilized in the wall of FIG. 2;

FIG. 10 is a sectional view taken along the plane lit-iii of FIG. 9;

FIG. 11 is a partial sectional view taken on the line 11-11 of FIG. 10.

Referring now in more detail to the drawings, wherein similar referencenumerals identify corresponding parts throughout the several views, inFIG. 2 the assembly of wall Milt is shown with a two retaining boltsystem at the top and a two retaining bolt system at the bottom;however, it is evident that this wall may also be assembled with aminimum of one retaining bolt in the top system and a minimum of oneretaining bolt in the bottom system. In assembling wall 100, FIG. 2,panel -iiiC is bolted against panel dill) by two bolts MD, placed in theupper holes 701) and WC of each pair of holes. Before panel 453C isplaced in edge-to-edge relationship with panel dt D, a pair of boltsStiC, are inserted, threaded shank in the same direction, in the lowerholes 768 and 76A of the panel 400, FIGS. 1 and 2. Washers $6, FIG. 3,are then slipped over the ends of bolts 80D and nuts 91, are then drawnup on bolts 80D on the left hand edge of 46C until panel ifiC is broughtin line with and securely against panel MD.

Two bolts, 8493, FIG. 2, are then inserted into and through holes '76!)and 7iiC in panel HEB, which is then placed in line with the twoprotruding bolts MC. The shank ends of bolts StEC are inserted in theircorresponding holes 7&3 and WA of panel 408 so that it may be movedagainst panel 4th). When panel 46B is in close relationship with panel46C the nuts 91 on bolts StiD are covered by the same recesses 72, FIGS.2 and 3, that also hold the heads of bolts 8433.

The nuts are then drawn upon bolts 8M3 to make panel MB part of the wallTil The heads of two bolts 33A are then seated in the countersunk end ofeach lower hole 7GB and A and panel 46A is ready to push over protrudingshank ends of bolts 80B. When panel 40A is pushed up to panel 40B thenuts 93 are drawn up on bolts 80B which completes four panel wall 106 asshown in FIG. 2. The two bolts 80A shown protruding from panel 40A, FIG.2, are left thus, to demonstrate the appearance of a wall when a fifthpanel is to be placed in juxtaposition to the left of panel 40A.

For making a plurality of panels from cementitious slurry, a cubicalrectangular mold 10, FIGS. 9 and 10, is used, having two easilyremovable side walls 11, and two similar removable end walls 12, allfour resting on base 14, composed of spaced hollow tubes 14a whichbecome individual panel bases, whereby the resulting cementitiouscasting may be easily sliced into separate panels 40, FIGS. 1 and 2.These hollow beams are held in fixed relationship by a system ofremovable, equally spaced end plugs 12a carried by end walls 12. Thisbase structure rests upon an elastomeric pad P, FIG. 10, which preventsloss of slurry through the spaces 13 of FIG. 9 lying between the hollowbeams.

Such mold structure is described and illustrated in the copeningapplication of Richard C. Gasmire, Serial No. 841,339, filed September21, 1959, assigned to the assignee of this application now abandoned.

To support a reinforcing mesh 30, FIGS. 9 and 10, in proper position tobe incorporated in each of the sliced panels there is provided aplurality of vertically disposed rod-like mesh retainers 50 which aredescribed in more detail in my said co-pending application Serial No.113,- 942. In the specific embodiment of the invention illustrated inthe drawings, FIGS. 9-11, four of such meshretainers 50 are provided foreach individual mesh 34), two of such mesh-retainers being disposed onone side of the particular mesh 30 and adjacent to the respective endsthereof, and the other two mesh-retainers 50 being disposed on theopposite side of the particular mesh 3% and closely adjacent to theother mesh-retainers. In principle, each mesh-retainer comprises arod-like element which may be inserted by an axial movement into themold in a fixed position closely adjacent to the particular mesh andthen rotated to effect a locking engagement between the mesh-retainer 50and one or more of the horizontally disposed mesh wires 31 of theparticular mesh 30.

A supporting structure 29, FIGS. 9 and 10, for the mesh-retainers 50 isprovided comprising a lower plate member 23, an upper plate member 22and welded side frame elements 25. A support structure 29 is provided ateach end of the mold 10 and is accurately located with respect to themold cavity by dowel pins 21 which pass through the lower plate 23 andinto suitable holes pro vided in the mold side walls 11. Plates 22 and23 are respectively provided with a plurality of aligned verticalapertures 26 and 27, FIG. 12, there being a set of such apertures foreach mesh-retainer 59.

After all of the mesh-retainers 50 have been locked in assembly with therespective reinforcing meshes 30, the mold 10 is then filled withappropriate concrete slurry which is permitted to harden to aself-supporting consistency.

When this condition is reached, the elements of each retainer 50 arewithdrawn from the prehardened concrete with a minimum of effort.

The use of such mesh-retainers 5i) permits positioning of thereinforcing mesh Stl within the cavity of mold 10 with a very highdegree of accuracy and positively locks each such mesh againstaccidental displacement that might be caused by the force of theconcrete being rapidly poured into such mold. At the same time, thepanel fastening apertures 70A 70D are accurately defined in each of thepanels.

The resulting cake of partiall-y hardened concrete is exposed byremoving the mold side walls 11 and end Walls 12, whereupon the cake issliced lengthwise by well known apparatus to form a plurality of panels49 each containing 4 an accurately positioned reinforcing mesh 30 andtraversed by four assembly holes 70A MED.

Curing and complete ha-rdening of the panels is then effected, either byair drying or autoclaving and the finished panels are then stripped fromthe mold base tubes 14a.

From the foregoing it will be apparent that the countersunk portions 72of holes 7th of the finished panels 45', FIGS. 1-4 are respectively madeby those parts of the cylindrical mesh retainers 547 which lie below theslurry fill of the mold 10.

Shoulder 71, FIG. 5, is formed in the concrete by means of a portion ofmesh retainer 50 and the smaller diameter portion 73 of hole 7%, FIGS. 1and 5, which receives the body 87 of bolt 80, FIGS. 6 and 7 is formed byanother portion thereof. In FIG. 11, enlarged portions of the retainersshown as phantoms 50A and 543B may be made to rest against verticalwi-res 32A and 32B of mesh to hold said mesh even more rigidly in place.

The remaining feature of the complex shoulder system in the hole 79,FIG. 5, is an offset shoulder formed by transverse wire 31A, which washeld in this relationship to the rest of the countersunk area by theinterlocking action of pairs of grooves of mesh-retainer 5'0.

Since in this type of Wall design the heads of any assembly bolts aremade inaccessible by the already closed joint between each twopreviously mounted panels, it is desirable that an internal controlmeans, at the bolthead area, be provided to prevent the assembly boltsfrom turning on their central axes in the holes when the nuts are beingdrawn tight on the opposite threaded ends, two panel widths beyond. Thisis accomplished by providing the assembly bolts 8!), FIGS. 6-8, with aregular hexagonal head topping an unusual shoulder 86, whose bottom face83 rests upon concrete shoulder area 71, FIGS. 3-5, of countersunk holdin the foamed panel 40. The curved portion 81 of said bolt partlyencircles wire 31A of transverse off-set wire shoulder, FIGS. 3-5, whilesimultaneously, fiat sideface 82 sets flush against the exposed straightline side of said transverse wire shoulder, thus preventing the boltfrom turning while the nut on thieaded end 89 of bolt 8% is beingtightened against washer 9i? protecting panel 40.

The countersunk chamber 72 of hole 76 FIGS. 3 and 4, is deep enough sothat there is space above the head of the traversing bolt for receivingthe threaded shank and the nut and washer of the bolt that holds theprevious two panels together. These latter projecting items being thusrecessed into the next panel, a flush edge-t0- edge panel assembly isprovided.

In assembling the panels, since each pair of holes is offset on oppositesides of the transverse wire 31 of reinforcing mesh, the flats 82 of theboltheads 85 are always inserted in the face-to-face relationship shownfor the two boltheads depicted in panels WB and 46C of FIG. 3.

A modification of the above four-hole assembly system would be to useonly upper pairs of holes and their alternating bolts while securing thebottom edges of the panels in a channelized or grooved foundation.

Another modification would be the reverse of this latter method in thatthe channel might be provided adjacent to the ceiling area and the lowerpair of holes 70 and their alternating bolts 8% would be used to giverigidity to the wall.

Another method of forming the cementitious panel of my invention is totack weld a specially-shaped locating rod to the reinforcing mesh, inthe manner taught generally in U.S. Patent No. 2,979,801. The abovereferred to specially-shaped locating rod has a minor diameter portionequal to the diameter of the transversely extending hole, and at one enda major diameter portion equal to the diameter of the countersunkportion or recessed portion of the panel. The specially-shaped 1ocatingrod is tack welded to the reinforcing mesh with the shoulder, formed atthe juncture of the minor and major diameter portions resting on thewire 31a. On rotation of the specially-shaped locating rod, the tackwelds Will the broken and the rod can then -be Withdrawn, leaving atransversely extending hole having a recessed portion terminating at thewire 310.

It will, of course, be understood that various other details ofconstruction may also 'be modified through a wide range withoutdeparting from the principles of this invention, and it is, therefore,not the purpose to limit the patent granted hereon, otherwise thannecessitated by the scope of the appended claim.

I claim:

A reinforced cementitous slab for construction purposes comprising arectangular mass of cementitious material having reinforcing meshdisposed intermediate and parallel to its major faces, said meshcomprising longitudinal and transverse wires, a bolt-receiving aperturetraversing said mass and disposed adjacent to the wires of said mesh,said aperture having an enlarged countersunk portion at one end andreceiving a bolt having a bolthead having a flattened peripheral chordportion, and a portion of one of the wires of said mesh traversing aperipheral chord area of said countersunk portion and being inengagement with the peripheral chord portion of the bolthead, therebypermitting the head of an inserted bolt to seat upon said wire portion.

References Cited by the Examiner UNITED STATES PATENTS 707,20'1 8/1902Brinkman 5222'8 1,214,964 2/1917 Small 52600 2,255,511 9/1941 Muller52285 X 2,341,757 2/ 1944 Brenneman 52562 FOREIGN PATENTS 134,523 1949Australia.

437,873 1926 Germany.

195,570 1923 Great Britain.

20 RICHARD W. COOKE, JR., Primary Examiner.

JOHN E. MURTAGH, Examiner.

